Lens with controlled light refraction

ABSTRACT

A lens for distribution of light from a light emitter having an emitter axis and defining an emitter plane. The lens including an emitter-adjacent base end forming an opening to an inner cavity surrounding the emitter. An inner-cavity surface includes an axis-adjacent first inner region configured for refracting emitter light rays away from the axis, a second inner region spaced from the first inner region and configured for refracting emitter light rays toward the axis, and a middle inner region joining and substantially cross-sectionally asymptotical to the first and second inner regions. The middle inner region is positioned with respect to the emitter to refract light away from the axis by progressively lesser amounts at positions progressively closer to the second inner region. The lens further has an outer surface including output regions each configured for refracting the light from a corresponding one of the inner regions such that at the outer surface light from each inner region is refracted substantially without overlapping light from the other inner regions.

FIELD OF THE INVENTION

This invention relates to lighting fixtures and, more particularly, to optics designed for desired LED light distribution. This invention also relates to the field of LED optics.

BACKGROUND OF THE INVENTION

In recent years, the use of light-emitting diodes (LEDs) for various common lighting purposes has increased, and this trend has accelerated as advances have been made in LEDs and in LED-array bearing devices, often referred to as “LED modules.” Indeed, lighting needs which have primarily been served by fixtures using high-intensity discharge (HID) lamps, halogen lamps, compact florescent light (CFL) and other light sources are now increasingly beginning to be served by LEDs. Creative work continues in the field of LED development, and also in the field of effectively utilizing as much of the light emitted from LEDs as possible.

Some efforts have been made to develop small lenses for directing light emitted by small LED packages, and utilizing lenses intended to redirect some amount of emitted light to form a desired illumination pattern. However, such lenses have tended to fall short of the most highly desirable performance in that some of the LED-emitted light is often lost.

Typically, some of the LED-emitted light rays are oriented at angles that previously would result in illumination of undesirable areas and thus produce less than fully efficient illumination patterns. Prior lenses would typically be arranged to either prevent these undesirable light rays from exiting the lens or to block these rays immediately upon their exiting the lens. Even though these steps were deemed necessary to achieve desired illumination patterns and to prevent so-called lighting “trespass,” they resulted in lost light and decreased efficiency of LED illuminators. It would be highly desirable to improve efficiency of output of light emitted by LEDs.

Typical LED illuminators emit light at a wide range of angles such that light rays reach the same area of the output surface of a lens at different angles. This has made it very difficult to control refraction of such light. As a result, only a portion of light being refracted is refracted in a desired direction, while the reminded exited the lens with very little control. It would be desirable to provide improved control of the direction of light exiting a lens.

Trespass lighting can be evaluated by more than just the amount of light emitted toward an undesirable direction; also to be considered is how far from the desired direction such light is directed. It would be highly beneficial to provide a lighting apparatus which produces a desired illumination pattern with a maximum amount of light emitted toward an area intended to be illuminated.

OBJECTS OF THE INVENTION

It is an object of the invention to provide improved LED optics (lenses) to overcome some of the problems and shortcomings of the prior art, including those referred to above.

Another object of the invention is to provide an LED lens with improved light-output efficiency.

Another object of the invention is to provide an LED lens with improved control of the direction of light exiting the optic.

How these and other objects are accomplished will become apparent from the following descriptions and the drawings.

SUMMARY OF THE INVENTION

This invention is a lens with improved efficiency of output of light from a light emitter which has an emitter axis and defines an emitter plane. It is preferred that the light emitter is an LED package which is free of a surrounding reflective surface. Such improved efficiency of light output from a light emitter is achieved with the inventive lens positioned over the emitter and specifically designed for controlled refraction of light at a lens output surface. The inventive lens provides useful output of almost all of the emitted light, including light emitted at angles which previously resulted in the loss of such light.

The inventive lens includes an emitter-adjacent base end forming an opening to an inner cavity surrounding the emitter. An inner-cavity surface preferably includes an axis-adjacent first inner region, a second inner region spaced from the first inner region, and a middle inner region which joins the first and second regions. The axis-adjacent first inner region is configured for refracting emitter light rays away from the axis. The second inner region is configured for refracting emitter light rays toward the axis. The middle inner region is substantially cross-sectionally asymptotical to the axis-adjacent and base-adjacent regions. It is preferred that the middle inner region is positioned with respect to the emitter to refract light away from the axis by progressively lesser amounts at positions progressively closer to the base-adjacent inner region.

The lens further has an outer surface which includes output regions each configured for refracting the light from a corresponding one of the inner regions such that at the outer surface light from each inner region is refracted substantially without overlapping light rays from the other inner regions.

In preferred embodiments, the outer surface output regions include an axis-adjacent first output region, a second output region spaced from the first output region, and a middle output region joining the first and second output regions. The axis-adjacent first output region is configured for receiving emitter light rays from the axis-adjacent first inner region and preferably refracting them away from the axis. The second output region is configured for receiving emitter light rays from the second inner region and preferably refracting them substantially away from the axis. The middle output region is configured for receiving emitter light rays from the middle inner region and preferably refracting them substantially away from the axis.

It is preferred that the outer surface further includes a base-adjacent outer-surface region which extends from the second output region and is substantially free from receiving any emitter light. The base-adjacent outer-surface region is preferably substantially orthogonal to the emitter plane.

In some preferred embodiments, the second inner region terminates before reaching the emitter plane. In such embodiments, the inner-cavity surface further preferably includes a base-adjacent inner region extending from the second inner region. The base-adjacent inner region is preferably substantially orthogonal to the emitter plane. The light rays emitted between the second inner region and the emitter plane preferably pass through the base-adjacent inner region substantially free of refraction.

In the embodiments just described, the lens preferably further includes a peripheral inner surface receiving light from the base-adjacent inner region. It is highly preferred that the peripheral inner surface is configured for total internal reflection (TIR) of such light toward the emitter axis. The peripheral inner surface is preferably formed by a peripheral cavity extending from the base end. It is preferred that the peripheral inner surface is configured for TIR of the light rays before they enter the peripheral cavity.

In preferred embodiments of the present invention, the axis-adjacent first inner region is substantially cross-sectionally concave and the second inner region is substantially cross-sectionally convex. It is further preferred that the middle inner region is substantially cross-sectionally linear. In other words, the middle inner region is preferably of substantially truncated conical shape.

The inner-cavity surface may be substantially rotationally symmetrical. The outer surface may also be substantially rotationally symmetrical such that the lens has a substantially annular cross-section made substantially parallel to the emitter plane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an enlarged perspective cross-sectional view of the inventive lens.

FIG. 2 is a greatly enlarged fragmentary cross-sectional side view of the lens of FIG. 1 showing refraction of the emitter light by inner-cavity surface regions and a peripheral inner cavity surface.

FIG. 3 is an enlarged fragmentary cross-sectional side view of the lens of FIG. 1 showing refraction of light emitted by the emitter at about the emitter axis and including a primary lens.

FIG. 4 is an enlarged fragmentary cross-sectional side view of the lens of FIG. 1 showing refraction of light emitted at the emitter axis.

FIG. 5 is an enlarged fragmentary cross-sectional side view showing non-refracted light direction of light emitted as in FIG. 3.

FIG. 6 is an enlarged fragmentary cross-sectional view of the lens of FIG. 1 showing refraction of light emitted from one site of the emitter axis.

FIG. 7 is an enlarged fragmentary cross-sectional view of the lens of FIG. 1 showing refraction of light emitted from another side of the emitter axis.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1-7 illustrate lens 10 which is a preferred embodiment of the invention. Lens 10 is for directing light from a light emitter 1 which has an emitter axis 2 and defines an emitter plane 3. Lens 10 includes an emitter-adjacent base end 12 forming an opening to an inner cavity 14 surrounding emitter 1. Cavity 14 defines a space between emitter 1 and an inner-cavity surface 20 such that emitter light goes through air to enter lens material at inner-cavity surface 20. Because air and the lens material, which may be acrylic or other suitable material, have different refraction indexes resulting in bending of the light at inner-cavity surface 20.

FIG. 2 best shows configuration of inner-cavity surface 20 which includes an axis-adjacent first inner region 21, a second inner region 22 spaced from first inner region 21, and a middle inner region 23 which joins first and second regions 21 and 22 and is substantially asymptotical to first and second inner regions 21 and 22.

FIGS. 1 and 3 best show that lens 10 further has an outer surface 30 which includes an axis-adjacent first output region 31, a second output region 32 spaced from axis-adjacent first output region 31, and a middle output region 33 joining first and second output regions 31 and 32. Each of output regions 31, 32 and 33 is configured for refracting the light from a corresponding one of inner regions 21, 22 and 23. Therefore, at outer surface 30 light from each inner region 21, 22 or 23 is refracted substantially without overlapping light rays from the other inner regions.

As also seen in FIG. 3, outer surface 30 further includes a base-adjacent outer-surface region 34 which extends from second output region 32 and is substantially free from receiving any emitter light. Base-adjacent outer-surface region 34 is substantially orthogonal to emitter plane 3. It should be appreciated that, since the base-adjacent outer-surface substantially does not participate in distribution of emitter light, it may have any configuration dictated by positioning and mounting of the lens or other factors such as material or space conservation.

FIG. 2 best illustrates that axis-adjacent first inner region 21 is configured for refracting emitter light rays 210 which pass through axis-adjacent first inner region 21 away from axis 2. This provides a broader distribution of the light emitted about axis and allows to enlarge the size of first output region 31 to achieve better refraction of light 210 outside lens 10. Light 210 received by the axis-adjacent first inner region 21 has the highest intensity. This is because typically the highest illumination intensity of the emitter light is concentrated about axis 2. By refracting light 210 away from axis 2, axis-adjacent inner region 21 allows for dispersion of such light 210 over a larger area. This improves uniformity of illumination intensity and substantially decreases a so-called “hot-spot” effect in a plot of illumination intensity distribution. FIG. 2 further illustrates that axis-adjacent first inner region 21 is substantially cross-sectionally concave.

As further seen in FIG. 2, second inner region 22 is configured for refracting emitter light rays toward the axis. It is seen in FIG. 2 that second inner region 22 is substantially cross-sectionally convex. Second inner region moves light 220, which mostly includes light emitted within about 30° from emitter plane 3, away from base-adjacent outer-surface region 34. As can be seen in FIG. 1, base-adjacent outer-surface region 34 is surrounded by structures 50 may serve to secure lens 10 with respect to emitter 1 or be a shield blocking emitter light from going in an undesirable direction. As a result, any light that would arrive at the base-adjacent region 34 would be blocked by such structures 50 and would be eventually lost. In prior lenses, because some of the light was lost, to meet goals of desired polar candela plots, the outer surface had to be designed to bend some of the axis-adjacent light to the sides to provide required illumination. By refracting light 220 toward emitter axis 2, this light is received by outer surface 30 at output region 32 which not only transmits light 220 out of lens 10 but also further refracts light 220 in a desired direction, i.e., away from emitter axis 2, as shown in FIG. 3. Therefore, since light 220 provides desired illumination at the sides of desired illumination patterns, there is no need for bending axis adjacent light 210 for such purpose.

In prior lenses the space between the emitter and inner lens surface was filled with an optical gel such that the emitter light passed therethrough without refraction and arrived to the outer surface at the same angle as emitted. In such prior lenses, the outer surface was the only vehicle for light refraction. When compared to such prior lenses, the configuration of outer surface 30 of lens 10 is unexpectedly substantially simpler then of those prior lenses. In the prior lenses, light arrived at the outer surface at substantially broad range of angles. Thus, almost all these angles had to be taken into account in forming that prior outer surface for refraction of light in a desirable direction. In lens 10, the direction of the majority of emitter light is initially substantially controlled by inner surface 20 and light from one of inner regions is received substantially by only a corresponding one output region of outer surface 30. As a result, each one output region of outer surface 30 receives light which arrives at substantially narrow sector of angles. This, coupled with improved efficiency which eliminates the need for bending axis-adjacent light for side illumination, simplifies the configuration of that output region of outer surface 30 for refraction of such light in a desired direction and, therefore, decreases a probability of an irregularity impact on the light-output direction.

It can be seen in FIG. 2 that middle inner region 23 is positioned with respect to emitter 1 to refract light away from axis 2 by progressively lesser amounts at positions progressively closer to the base-adjacent inner region. In some cases, middle region 23 may be configured and positioned to allow emitter light to pass therethrough with substantially no refraction. As best shown in FIG. 2, middle inner region 23 is substantially cross-sectionally linear. In other words, middle inner region 23 is of substantially truncated conical shape.

As best seen in FIG. 3, axis-adjacent first output region 31 is configured for receiving emitter light rays 210 from axis-adjacent first inner region 21 and further refracting them away from axis 2. Second output region 32 is configured for receiving emitter light rays 220 from second inner region 22 and refracting them substantially away from axis 22. Middle output region 33 is configured for receiving emitter light rays 230 from middle inner region 23 and refracting them substantially away from axis 2.

It should be understood that shown configuration of outer surface 30 is just an exemplary configuration. Outer surface 30 can have other configurations which would be dictated by an intended illumination pattern.

As further seen in the FIGURES, second inner region 22 terminates before reaching emitter plane 3. Inner-cavity surface 20 further includes a base-adjacent inner region 24 extending from second inner region 22. Base-adjacent inner region 24 is substantially orthogonal to emitter plane 3 and is oriented for substantially non-refracted passing through of light 240 emitted between second inner region 22 and emitter plane 3.

Lens 10 further includes a peripheral inner surface 40 which receives light 240 from base-adjacent inner region 24. Peripheral inner surface 40 is configured for total internal reflection (TIR) of light 240 toward emitter axis 2. Thus, light 240 is retrieved from lens 10 for useful illumination rather than being lost. Peripheral inner surface 40 is formed by a peripheral cavity 41 extending from base end 12. As best seen in FIG. 2, peripheral inner surface 41 is configured for TIR of light rays 240 before they enter peripheral cavity 41.

FIG. 1 shows inner-cavity surface 20 substantially rotationally symmetrical. Peripheral cavity 41 and peripheral inner surface 40 are also substantially rotationally symmetrical. The embodiment illustrated in FIG. 1 further shows outer surface 30 as substantially rotationally symmetrical such that lens 10 has a substantially annular cross-section in a plane substantially parallel to emitter plane 3. Alternatively, the inner and outer surfaces can have shapes that result in substantially oval or ovoid cross-section made in a plane substantially parallel to the emitter plane. In other words, these surfaces may have symmetries other than rotational. It should be further appreciated that, depending on the intended illumination pattern, the inventive lens may be shaped without a symmetry and have asymmetrical surfaces.

While the principles of the invention have been shown and described in connection with specific embodiments, it is to be understood that such embodiments are by way of example and are not limiting. 

1. A lens for distribution of light from a light emitter having an emitter axis and defining an emitter plane, comprising: an emitter-adjacent base end forming an opening to an inner cavity surrounding the emitter; and an inner-cavity surface including (a) an axis-adjacent first inner region configured for refracting emitter light rays away from the axis, (b) a second inner region spaced from the first inner region and configured for refracting emitter light rays toward the axis, and (c) a middle inner region joining and substantially cross-sectionally asymptotical to the first and second inner regions, the middle inner region being positioned with respect to the emitter to refract light away from the axis by progressively lesser amounts at positions progressively closer to the second inner region.
 2. The lens of claim 1 further including an outer surface having output regions each configured for refracting the light from a corresponding one of the inner regions such that at the outer surface light from each inner region is refracted substantially without overlapping light from the other inner regions.
 3. The lens of claim 2 wherein the outer surface output regions include: an axis-adjacent first output region configured for receiving emitter light rays from the axis-adjacent first inner region and refracting them away from the axis; a second output region spaced from the first output region and configured for receiving emitter light rays from the second inner region and refracting them substantially away from the axis; and a middle output region joining the first and second output regions and configured for receiving emitter light rays from the middle inner region and refracting them substantially away from the axis.
 4. The lens of claim 3 wherein the outer surface further includes a base-adjacent outer-surface region extending from the second output region and being substantially free from receiving any emitter light.
 5. The lens of claim 4 wherein the base-adjacent outer-surface region is substantially orthogonal to the emitter plane.
 6. The lens of claim 4 wherein the inner-cavity surface further includes a base-adjacent inner region extending from the second inner region and configured such that the light rays emitted between the second inner region and the emitter plane pass through the base-adjacent inner region substantially free of refraction.
 7. The lens of claim 6 further including a peripheral inner surface receiving light from the base-adjacent inner region, the peripheral inner surface configured for total internal reflection (TIR) of such light toward the output regions.
 8. The lens of claim 7 wherein the peripheral inner surface is formed by a peripheral cavity extending from the base end, the peripheral inner surface being configured for TIR of the light rays before they enter the peripheral cavity.
 9. The lens of claim 2 wherein the inner-cavity surface is substantially rotationally symmetrical.
 10. The lens of claim 9 wherein the outer surface is substantially rotationally symmetrical such that the lens has a substantially circular cross-section in a plane substantially parallel to the emitter plane.
 11. The lens of claim 1 wherein the second inner region is substantially cross-sectionally convex.
 12. The lens of claim 1 wherein the middle inner region is substantially cross-sectionally linear.
 13. The lens of claim 1 wherein the axis-adjacent inner region is substantially cross-sectionally concave.
 14. The lens claim 13 wherein the second inner region is substantially cross-sectionally convex.
 15. The lens of claim 14 wherein the middle inner region is substantially cross-sectionally linear.
 16. The lens of claim 14 wherein the inner-cavity surface is substantially rotationally symmetrical.
 17. The lens of claim 1 wherein the second inner region terminates before reaching the emitter plane.
 18. The lens of claim 17 wherein the inner-cavity surface further includes a base-adjacent inner region extending from the second inner region and configured such that the light rays emitted between the second inner region and the emitter plane pass through the base-adjacent inner region substantially free of refraction.
 19. The lens of claim 18 further including a peripheral inner surface receiving light from the base-adjacent inner region, the peripheral inner surface configured for total internal reflection (TIR) of such light toward the emitter axis.
 20. The lens of claim 17 further including a peripheral inner surface receiving light emitted between the base-adjacent inner surface and the emitter plane, the peripheral inner surface configured for total internal reflection (TIR) of such light toward the emitter axis.
 21. The lens of claim 20 wherein the peripheral inner surface is formed by a peripheral cavity extending from the base end, the peripheral inner surface being configured for TIR of the light rays before they enter the peripheral cavity. 